Display device and method of manufacturing same

ABSTRACT

A method of manufacturing a display device includes providing a display substrate divided into a plurality of emission regions, and a non-emission region adjacent the emission regions; forming a black matrix on the display substrate, the black matrix corresponding to the non-emission region; and forming a plurality of color patterns on the display substrate through a solution process, the plurality of color patterns corresponding to the emission regions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/061,430, filed Oct. 1, 2020, which is a continuation of U.S. patentapplication Ser. No. 16/403,376, filed May 3, 2019, now U.S. Pat. No.10,811,467, which is a divisional of U.S. patent application Ser. No.15/041,862, filed Feb. 11, 2016, now U.S. Pat. No. 10,325,962, whichclaims priority to and the benefit of Korean Patent Application No.10-2015-0051987, filed Apr. 13, 2015, the entire content of all of whichis incorporated herein by reference.

BACKGROUND

The present disclosure herein relates to a display device capable ofimproved display quality and to a method of manufacturing the same.

A display device may include a display substrate and a variety offunctional films. The functional films reduce reflectance of externallight from a display device to enhance outside visibility of the displaydevice.

As the number of the functional films increases with respect to a samedisplay substrate, the display device becomes thicker. As the number ofthe functional films increases, outside visibility may be enhanced,although flexibility of the display device may be reduced.

SUMMARY

The present disclosure provides a flexible display device with enhancedvisibility.

The present disclosure also provides a method of manufacturing a displaydevice, the method with a reduced process cost and a reduced processtime.

A method of manufacturing a display device according to an embodiment ofthe present invention includes providing a display substrate dividedinto a plurality of emission regions, and a non-emission region adjacentthe emission regions; forming a black matrix on the display substrate,the black matrix corresponding to the non-emission region; and forming aplurality of color patterns on the display substrate through a solutionprocess, the plurality of color patterns corresponding to the emissionregions.

The solution process may include an ink-jet process.

The forming the black matrix may include performing a photolithographyprocess.

The forming the black matrix may include coating the display substratewith a photosensitive material to form a photosensitive layer;selectively irradiating the photosensitive layer by using a mask; bakingthe photosensitive layer; and developing the photosensitive layer.

The forming the black matrix may further include providing plasma on thedisplay substrate to surface-treat the black matrix.

The forming the color patterns may include providing a color solution torespective ones of the emission regions to form a plurality of colorsolution layers; and drying the color solution layers.

The method may further include drying the color solution layers usingheat.

A temperature of the heat may be about 150 degrees (° C.) or below.

Each of the color patterns may be thinner than a respective one of thecolor solution layers, and may be thinner than an adjacent region of theblack matrix.

Adjacent ones of the color patterns may have different colors.

The display substrate may include organic light emitting devices at theemission regions, respectively; and an encapsulation layer sealing theorganic light emitting devices and including an inorganic materialdeposited on the organic light emitting devices.

The black matrix and the color patterns may be directly on theencapsulation layer.

A display device according to an embodiment of the present invention mayinclude a display substrate divided into a plurality of emissionregions, and a non-emission region adjacent the plurality of emissionregions; a black matrix on the display substrate and corresponding tothe non-emission region; and a color filter layer at a same layer as theblack matrix, and including color patterns corresponding to the emissionregions, respectively, wherein each of the color patterns is thinnerthan a respective adjacent portion of the black matrix.

The display substrate may include a base substrate; organic lightemitting devices on the base substrate and corresponding to the emissionregions; and a thin film encapsulation layer on the base substrate andsealing the organic light emitting devices, and wherein the color filterlayer contacts the thin film encapsulation layer.

A range of a thickness of the thin film encapsulation layer may be fromabout 1 μm to about 10 μm.

The display device may further include a protective layer having a flatsurface on the color filter layer.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings are included to provide a furtherunderstanding of embodiments of the present invention, and areincorporated in and constitute a part of this specification. Thedrawings illustrate exemplary embodiments of the present invention and,together with the description, serve to explain aspects of the presentinvention. In the drawings:

FIG. 1 illustrates a perspective view of a display device according toan embodiment of the present invention;

FIG. 2 illustrates a cross-sectional view taken along the line I-I′ inFIG. 1 ;

FIG. 3 illustrates an equivalent circuit diagram of a portion of adisplay substrate according to an embodiment of the present invention;

FIGS. 4A to 4B are cross-sectional views respectively illustratingportions of a display device according to an embodiment of the presentinvention;

FIG. 5 illustrates a plan view of a portion of a color filter layeraccording to an embodiment of the present invention; and

FIG. 6 illustrates a cross-sectional view of a portion of a displaydevice according to an embodiment of the present invention.

FIG. 7 illustrates a flow chart of a method of manufacturing a displaydevice according to an embodiment of the present invention.

FIGS. 8A to 8H are cross-sectional views sequentially illustrating amethod of manufacturing a display device according to an embodiment ofthe present invention.

DETAILED DESCRIPTION

Hereinafter, embodiments of the present invention will be described indetail with reference to drawings.

It will be understood that, although the terms “first”, “second”,“third”, etc., may be used herein to describe various elements,components, regions, layers, and/or sections, these elements,components, regions, layers and/or sections should not be limited bythese terms. These terms are used to distinguish one element, component,region, layer or section from another element, component, region, layeror section. Thus, a first element, component, region, layer, or sectiondiscussed below could be termed a second element, component, region,layer, or section, without departing from the spirit and scope of thepresent invention.

Spatially relative terms, such as “beneath”, “below”, “lower”, “under”,“above”, “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. It will beunderstood that the spatially relative terms are intended to encompassdifferent orientations of the device in use or in operation, in additionto the orientation depicted in the figures. For example, if the devicein the figures is turned over, elements described as “below” or“beneath” or “under” other elements or features would then be oriented“above” the other elements or features. Thus, the example terms “below”and “under” can encompass both an orientation of above and below. Thedevice may be otherwise oriented (e.g., rotated 90 degrees or at otherorientations) and the spatially relative descriptors used herein shouldbe interpreted accordingly.

Further, it will also be understood that when one element, component,region, layer and/or section is referred to as being “between” twoelements, components, regions, layers, and/or sections, it can be theonly element, component, region, layer and/or section between the twoelements, components, regions, layers, and/or sections, or one or moreintervening elements, components, regions, layers, and/or sections mayalso be present.

The terminology used herein is for the purpose of describing particularembodiments and is not intended to be limiting of the present invention.As used herein, the singular forms “a” and “an” are intended to includethe plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprise,”“comprises,” “comprising,” “includes,” “including,” and “include,” whenused in this specification, specify the presence of stated features,integers, steps, operations, elements, and/or components, but do notpreclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items. Expressions such as “atleast one of,” when preceding a list of elements, modify the entire listof elements and do not modify the individual elements of the list.Further, the use of “may” when describing embodiments of the presentinvention refers to “one or more embodiments of the present invention.”Also, the term “exemplary” is intended to refer to an example orillustration.

It will be understood that when an element or layer is referred to asbeing “on,” “connected to,” “coupled to,” “connected with,” “coupledwith,” or “adjacent” another element or layer, it can be “directly on,”“directly connected to,” “directly coupled to,” “directly connectedwith,” “directly coupled with,” or “directly adjacent” the other elementor layer, or one or more intervening elements or layers may be present.Further “connection,” “connected,” etc. may also refer to “electricalconnection,” “electrically connect,” etc. depending on the context inwhich they are used as those skilled in the art would appreciate. Whenan element or layer is referred to as being “directly on,” “directlyconnected to,” “directly coupled to,” “directly connected with,”“directly coupled with,” or “immediately adjacent” another element orlayer, there are no intervening elements or layers present.

As used herein, the term “substantially,” “about,” and similar terms areused as terms of approximation and not as terms of degree, and areintended to account for the inherent deviations in measured orcalculated values that would be recognized by those of ordinary skill inthe art.

As used herein, the terms “use,” “using,” and “used” may be consideredsynonymous with the terms “utilize,” “utilizing,” and “utilized,”respectively.

FIG. 1 illustrates a perspective view of a display device according toan embodiment of the present invention, FIG. 2 illustrates across-sectional view taken along the line I-I′ in FIG. 1 , and FIG. 3illustrates an equivalent circuit diagram of a portion of a displaysubstrate according to an embodiment of the present invention.Hereinafter, a display device DS will be described with reference toFIGS. 1 to 3 .

The display device DS has a planar shape defined by a first directionDR1 and a second direction DR2 crossing the first direction DR1. Thedisplay device DS includes a display substrate DP, a color filter layerCFL, and a protective layer PTL that are sequentially stacked in anupward direction DR3 (hereinafter, referred to as a third directionDR3).

The display substrate DP is configured to display an image according toan electrical signal. In the present embodiment, the display substrateDP includes a display surface for displaying an image towards the thirddirection DR3.

The display substrate DP may be one or more of a variety of displaypanels. For example, a liquid crystal display panel, an organic lightemitting display panel, an electrophoretic display panel, or anelectrowetting display panel may be applied to the display substrate DP.

A flexible display panel, which is flexible and easily manufactured insmall size, may be applied to the display substrate DP according toembodiments of the present invention. Hereinafter, the display substrateDP of the present embodiment is an organic light emitting display panel,but the present invention is not limited thereto.

The display substrate DP includes a display layer DPL and a thin filmencapsulation layer TFE. The display layer DPL includes a plurality ofpixels that are configured to respectively receive an electrical signalto generate an image.

FIG. 3 exemplarily illustrates one pixel PX(i,j) among the plurality ofpixels that is connected to an i-th gate line GLi and to a j-th dataline DLj. Each of the plurality of pixels may have a structure that isthe same or substantially the same as the illustrated pixel PX(i,j).However, this illustration is only exemplary, and the configuration andarrangement of the PX(i,j) may be changed.

Referring to FIG. 3 , the pixel PX(i,j) is configured to receive a gatesignal from the i-th gate line GLi, and to receive a data signal fromthe j-th data line DLj. In addition, the PX(i,j) is configured toreceive a first power supply voltage ELVDD from a power line KL. Thepixel PX(i,j) includes a first thin film transistor TFT1, a second thinfilm transistor TFT2, a capacitor Cap, and an organic light emittingdevice OLED.

The first thin film transistor TFT1 is configured to output a datasignal applied to the j-th data line DLj in response to the gate signalapplied to the i-th gate line GLi. The capacitor Cap is configured to becharged with a voltage corresponding to the data signal received fromthe first thin film transistor TFT1.

The second thin film transistor TFT2 is connected to the organic lightemitting device OLED, and is configured to control a drive currentflowing in the organic light emitting device OLED corresponding to acharge amount stored in the capacitor Cap.

The organic light emitting device OLED includes a first electrodeconnected to the second thin film transistor TFT2, and a secondelectrode configured to receive the second power supply voltage ELVSS.In the present embodiment, the second power supply voltage ELVSS has alower voltage level than the first power supply voltage ELVDD.

In addition, the organic light emitting device OLED at least includes anorganic emission layer between the first and second electrodes. Theorganic light emitting device OLED is configured to emit light during aturn-on period of the second thin film transistor TFT2.

The thin film encapsulation layer TFE seals a plurality of pixels. Thethin film encapsulation layer TFE may include an inorganic film, or mayhave a structure in which an inorganic film and an organic film arealternately stacked. The thin film encapsulation layer TFE generally hasa transparent characteristic, so that an image may be viewed fromoutside.

The color filter layer CFL includes a black matrix BM and color patternsCP. The black matrix BM and the color patterns CP may be located at asame layer. In the present embodiment, the black matrix BM and the colorpatterns CP are directly on the thin film encapsulation layer TFE to bein contact with an upper surface of the thin film encapsulation layerTFE.

The black matrix BM may be formed of a light-shielding material, and mayabsorb light incident on the black matrix BM. Accordingly, the blackmatrix BM may generally have a color of a black series (e.g., arelatively dark color).

The color patterns CP have at least two different colors. In the presentembodiment, the color patterns CP include a first color pattern CP-R, asecond color pattern CP-G, and a third color pattern CP-B respectivelyhaving different colors from each other (see FIG. 5 ).

Adjacent ones of the color patterns CP may have colors different fromeach other. In the present embodiment, the first, second, and thirdcolor patterns CP-R, CP-G, and CP-B, which have different colors fromeach other, are sequentially arranged along the first direction DR1.

The present illustration is only exemplary, and the color patterns CPmay have four or more colors in other embodiments of the presentinvention. Further, adjacent ones of the color patterns CP may have thesame or substantially the same color as each other. The color filterlayer CFL according to the present embodiment may be embodied in manydifferent forms, and the present invention should not be construed asbeing limited to the embodiments set forth herein.

The protective layer PTL is located on the color filter layer CFL toprotect the color filter layer CFL. The protective layer PTL provides aflat surface on an upper surface of the display device DS as definedtowards the third direction D3. The flat surface corresponds to a wholesurface of the display device DS. This illustration is only exemplary,and the protective layer PTL may be omitted in a display device DSaccording to other embodiments of the present invention.

FIGS. 4A and 4B are cross-sectional views respectively illustratingportions of a display device according to an embodiment of the presentinvention, and FIG. 5 illustrates a plan view of a portion of a colorfilter layer according to an embodiment of the present invention.

FIG. 4A illustrates a cross-sectional view of a region including thefirst thin film transistor TFT1 and the capacitor Cap illustrated inFIG. 3 , and FIG. 4B illustrates a cross-sectional view of a regionincluding the second thin film transistor TFT2 and the organic lightemitting device OLED illustrated in FIG. 3 .

Hereinafter, a layer structure of a display device DS according to anembodiment of the present invention will be described in detail withreference to FIGS. 4A to 5 . Components that are the same orsubstantially similar to the components illustrated in FIGS. 1 to 3 aregiven the same reference numeral, and repeated descriptions thereof maybe omitted.

Referring to FIGS. 4A and 4B, the display layer DPL includes a baselayer SUB, a first thin film transistor TFT1, a second thin filmtransistor TFT2, a capacitor Cap, and an organic light emitting deviceOLED. The base layer SUB may include a glass substrate, a metalsubstrate, and/or a flexible plastic substrate.

A first semiconductor pattern AL1 of the first thin film transistorTFT1, a second semiconductor pattern AL2 of the second thin filmtransistor TFT2, and a first insulating layer 10 are located on the baselayer SUB. The first insulating layer 10 covers the first and secondsemiconductor patterns AL1 and AL2. A first electrode CE1 of thecapacitor Cap may be located on the first insulating layer 10.

A control electrode GE1 (hereinafter, referred to as a first controlelectrode GE1) of the first thin film transistor TFT1, a controlelectrode GE2 (hereinafter, referred to as a second control electrodeGE2) of the second thin film transistor TFT2, and a second insulatinglayer 20 are located on the first insulating layer 10. The secondinsulating layer 20 covers the first and second control electrodes GE1and GE2.

Each of the first and second insulating layers 10 and 20 includes anorganic film and/or an inorganic film, and may include a plurality ofthin films.

An input electrode SE1 (hereinafter, referred to as a first inputelectrode SE1) and an output electrode DE1 (hereinafter, referred to asa first output electrode DE1) of the first thin film transistor TFT1, aninput electrode SE2 and an output electrode DE2 (hereinafter,respectively referred to as second input electrode SE2 and as secondoutput electrode DE2) of the second thin film transistor TFT2, and athird insulating layer 20 are located on the second insulating layer 20.

A second electrode CE2 of the capacitor Cap may be located on the secondinsulating layer 20. The third insulating layer 30 covers the firstinput electrode SE1, the first output electrode DE1, the second inputelectrode SE2, the second output electrode DE2, and the second electrodeCE2.

The first input electrode SE1 is connected to the first semiconductorpattern AL1 through a first through hole CH1 penetrating the secondinsulating layer 20, and the first output electrode DE1 is connected tothe first semiconductor pattern AL1 through a second through hole CH2penetrating the second insulating layer 20. In the same or similarmanner, the second input electrode SE2 is connected to the secondsemiconductor pattern AL2 through a third through hole CH3 penetratingthe second insulating layer 20, and the second output electrode DE2 isconnected to the second semiconductor pattern AL2 through a fourththrough hole CH4 penetrating the second insulating layer 20.

The organic light emitting device OLED and a pixel defining layer PDLare located on the third insulating film 30. The pixel defining layerPDL exposes a region of the organic light emitting device OLED on thethird insulating film 30. The pixel defining layer PDL substantiallydefines an emission region of the OLED.

The organic light emitting device OLED includes an anode electrode AE,an emission pattern EML, a cathode electrode CE, a hole transport regionCL1 (or, first common layer) between the anode electrode AE and theemission pattern EML, and an electron transport region CL2 (or, a secondcommon layer) between the emission pattern EML and the cathode electrodeCE.

The anode electrode AE is located on the third insulating layer 30. Aplurality of anode electrodes AE is provided at respective emissionregions and corresponding to respective pixels. The pixel defining layerPDL partially overlaps the anode electrode AE to expose at least some ofthe anode electrode AE. The anode electrode AE is connected to thesecond output electrode DE2 thorough a fifth through hole CH5penetrating the third insulating layer 30.

The hole transport region CL1 is located on the anode electrode AE tocover the anode electrode AE and the pixel defining layer PDL, and mayinclude at least one of a hole injection layer, a hole transport layer,and/or a single layer having both a hole injection function and a holetransport function.

The emission layer EML is located on the hole transport region CL1. Aplurality of emission layers EML is provided to respectively overlap theemission regions. The emission pattern EML may include a fluorescentmaterial or a phosphorescent material, and may generate a light havingone color, or may generate a light in which at least two colors aremixed.

The electron transport region CL2 is located on the emission pattern EMLto cover the emission pattern EML and the hole transport region CL1. Theelectron transport region CL2 may include at least any one of anelectron transport material and an electron injection material. Theelectron transport region CL2 may be an electron transport layerincluding an electron transport material, or may be a single electroninjection/transport layer including an electron transport material andan electron injection material.

The cathode electrode CE is located on the electron transport region CL2to face the anode electrode AE, and may be formed of a material having alow work function to facilitate electron injection.

The cathode electrode CE and the anode electrode AE may be formed ofdifferent materials according to an emission type. For example, when thedisplay device according to an embodiment of the present invention is atop emission type, the cathode electrode CE may be a transmissiveelectrode, and the anode AE may be a reflective electrode.Alternatively, for example, when the display device according to anembodiment of the present invention is a bottom emission type, thecathode electrode CE may be a reflective electrode, and the anode AE maybe a transmissive electrode. The display device DS according toembodiments of the present invention may include an organic lightemitting device of various suitable structures, and the presentinvention should not be limited to any one of the embodiments set forthherein.

The cathode electrode CE is located on/below the thin film encapsulationlayer TFE, which covers a front surface of the cathode electrode CE toseal the organic light emitting device OLED.

The thin film encapsulation layer TFE may have a thickness ranging fromabout 1 μm to about 10 μm. The display substrate DP includes the thinfilm encapsulation layer TFE, thus being able to achieve a thin displaydevice. The thin film encapsulation layer TFE may include a plurality ofinorganic films. Each of the inorganic films may include at least anyone of a silicon nitride or a silicon oxide. In addition, the thin filmencapsulation layer TFE may further include another functional layerbetween the inorganic films.

Referring to FIG. 5 , the black matrix BM overlaps a non-emission regionNLA, and each of the color patterns CP overlap an emission region LA.The black matrix BM has a grid shape in a plane defined by the firstdirection DR1 and the second direction DR2.

A plurality of openings exposing each of a plurality of regionscorresponding to emission regions LA are defined by the black matrix BM.The color patterns CP are filled in the plurality of openings.

The black matrix BM may include an organic material having a high lightabsorption rate, and may include, for example, a black pigment or ablack dye.

The color patterns CP are respectively located at regions correspondingto the emission regions LA. Accordingly, the color patterns CP may bespaced from each other in a matrix shape.

The color patterns CP may have colors different from each other.Adjacent ones of the color patterns CP may have colors different fromeach other. For example, the first, second, and third color patternsCP-R, CP-G, and CP-B, which are sequentially arranged in the firstdirection DR1, may respectively have a red color, a green color, and ablue color.

Referring back to FIGS. 4A and 4B, the black matrix BM overlaps thefirst thin film transistor TFT1, the second thin film transistor TFT2,and the capacitor Cap, which are located at the non-emission region NLA.In addition, each of the color patterns CP may overlap the organic lightemitting device OLED located at an emission region LA.

Thicknesses of one or all of the color patterns CP may be different froma thickness of the black matrix BM. For example, referring to FIG. 4B,the thickness TH_(CP) of any one color pattern CP may be less than thethickness TH_(BM) of the black matrix BM.

The color patterns CP according to an embodiment of the presentinvention is formed by a solution process. For example, moisture isremoved while the color patterns CP are provided as a liquid and dried,and accordingly, each of the color patterns may be thinner than theblack matrix BM. Details thereof will be described below.

Referring back to FIGS. 4A and 4B, the protective layer PTL is locatedon the color filter layer CFL to cover the color patterns CP and theblack matrix BM. The protective layer PTL protects the color filterlayer CFL, and provides a flat surface on the color filter layer CFL.

As described above, the color patterns CP have different thickness thanthe black matrix BM, thus potentially forming a slightly uneven topsurface. The protective layer PTL improves an uneven surface formed bythe color filter layer CFL. Accordingly, a user may visually recognizean image displayed on a uniform flat surface regardless of a potentiallyuneven surface of the color filter layer CFL.

FIG. 6 illustrates a cross-sectional view of a portion of a displaydevice according to an embodiment of the present invention. In FIG. 6 ,for an easy description of an embodiment of the present invention, adisplay device DS in which some of the elements (or components) areomitted is illustrated based on one emission region LA2.

For example, an organic light emitting device OLED in FIG. 6substantially corresponds to an organic emission layer EML (see FIG.4B). The same or substantially the same elements (or components) asthose illustrated in FIGS. 1 to 5 are given the same reference numerals,and a description thereof may be omitted.

FIG. 6 illustrates optical paths that may occur in a display device DS.As illustrated in FIG. 6 , the display device DS is influenced by atleast three lights.

An internal light L-EL is generated inside the display device DS to bedischarged to outside the display device DS toward the third directionDR3. An external light L-IN is incident to the display device DS, and areflected light L-RF component of the external light L-IN is reflectedfrom the display device DS to be emitted.

The organic light emitting device OLED generates the internal light L-ELhaving a set or predetermined color to emit the generated internal lightL-EL to outside. The color of the internal light L-EL generated by theorganic light emitting device OLED may be substantially the same as acolor of a color pattern overlapping the organic light emitting deviceOLED.

For example, the organic light emitting device OLED of the presentexample emits a light L-EL of green color, and the color pattern CP-Gmay have a green color that is substantially similar to the green colorof the light L-EL. The internal light L-EL may be partially absorbed bythe thin film encapsulation layer TFE, the color filter layer CFL, andthe protective layer PTL when passing through the thin filmencapsulation layer TFE, the color filter layer CFL, and the protectivelayer PTL.

The external light L-IN may be a visible light (e.g., sunlight). A firstportion light La component of the external light L-IN may be reflectedfrom a surface (e.g., an upper surface) of the protective layer PTL.Even when the external light L-IN enters the protective layer PTLwithout being reflected from the surface, a second portion light Lbcomponent of the external light L-IN may be absorbed by the protectivelayer PTL.

A third portion light Lc component of the external light L-IN may passthrough the color pattern CP-G to be incident on the organic lightemitting device OLED. The third portion light Lc may be a component ofthe external light L-IN that passes through the color pattern CP-G.

Wavelengths of visible light may be generally classified into a redwavelength region ranging from about 550 nm to about 750 nm, a greenwavelength region ranging from about 480 nm to about 550 nm, and a bluewavelength region ranging from about 350 nm to about 480 nm.

As described above, the color pattern CP-G of the present example has agreen color, thus passing only light in the green wavelength region.Accordingly, the third portion light Lc component of the external lightL-IN has a wavelength corresponding to the color green. In the organiclight emitting device OLED, at least a portion of the third portionlight Lc is reflected to form a fourth portion light Ld.

The fourth portion light Ld is discharged outside the display device DSthrough the thin film encapsulation layer TFE, the color pattern CP-G,and the protective layer PTL, and may be visually recognized as thereflected light L-RF. The fourth portion light Ld is a light immediatelyreflected from the organic light emitting device OLED, and the reflectedlight L-RF may be a light emitted outside through the thin filmencapsulation layer TFE, the color pattern CP-G, and the protectivelayer PTL. It should be noted that the fourth portion light Ld may bepartially absorbed or scattered by the thin film encapsulation layerTFE, the color pattern CP-G, and/or the protective layer PTL.

Accordingly, the reflected light L-RF may have a lower intensity than(e.g., may be a component of) the fourth portion light Ld. In addition,the reflected light L-RF may have a lower intensity than the externallight L-In by about 15% or less. Accordingly, the display deviceaccording to an embodiment of the present invention further includes thecolor filter layer CFL, thus being able to obtain an effect of reducingor preventing reflection of external light L-IN.

An optical film, such as a polarizing film or a retardation film, maygenerally reduce light efficiency of a display device by refracting orreflecting the internal light L-EL. The display device according to anembodiment of the present invention may omit the optical film, and mayinclude the color filter layer CFL to reduce external light reflectance,thus providing a display device DS with improved visibility.

The optical film is generally provided in the form of a film, thusgenerally increasing thickness of the display device. In addition, anadhesive layer may be used to apply the optical film to the displaydevice. Therefore, the increased thickness of the display device mayaffect flexibility of the display device.

Conversely, the color filter layer CFL may be directly located on thedisplay substrate DPL, and may be formed through a patterning processand the like, thus being able to be thinner than the optical film.According to an embodiment of the present invention, because the opticalfilm may be omitted while a single color filter layer CFL is included,it is possible to reduce the thickness of the display device DS.

Generally, the thinner the display device is, the more flexible thedisplay device becomes. Therefore, according to an embodiment of thepresent invention, it is possible to realize a thin display device thatis foldable/bendable.

FIG. 7 illustrates a flow chart of a method of manufacturing a displaydevice according to an embodiment of the present invention, and FIGS. 8Ato 8H are cross-sectional views sequentially illustrating a method ofmanufacturing a display device according to an embodiment of the presentinvention. Hereinafter, a method of manufacturing a display deviceaccording to an embodiment of the present invention will be describedwith reference to FIGS. 7 to 8H.

As illustrated in FIGS. 7 and 8A, a method of manufacturing a displaydevice includes providing a display substrate S100, and forming a colorfilter layer S200. For an easy description, the display substrate DP isillustrated to include only some of the possible configurations.

Referring to FIGS. 7, 8B, and 8C, a black matrix BM is formed on adisplay substrate DP (S210). The black matrix BM may be formed throughvarious suitable processes, and may be directly formed on a thin filmencapsulation layer TFE. In the present embodiment, the black matrix BMmay be formed through a photolithography process. Therefore, patternaccuracy and reliability of the black matrix BM is improved, and thus,the black matrix BM may play a role as a barrier rib in a subsequentprocess.

First, a photosensitive film PS is formed by coating a photosensitivematerial on a thin film encapsulation layer TFE. A mask MSK providedwith a plurality of transmission regions TA and a shielding region(s) SAis placed on or above the photosensitive film PS, and the photosensitivefilm PS is patterned to form a black matrix BM.

Light LS is selectively transmitted through the mask MSK (e.g., throughthe transmission regions TA), and is incident on the photosensitivelayer PS. In this embodiment, the photosensitive film PS may be apositive type. Accordingly, regions corresponding to the transmissionregions TA among the photosensitive film PS are cross-linked by thelight LS. A region corresponding to the shielding region SA is removedthrough a developing process using a developing solution, and thecross-linked portion(s) remains to form the black matrix BM.

The above description is only exemplary, and the photosensitive film PSaccording to an embodiment of the present invention may be a negativetype. That is, the black matrix BM may be formed through a mask havingtransmission regions that correspond to a shape of the black matrix, asopposed to transmission regions that correspond to the emission regions.

As illustrated in FIG. 8D, a method of manufacturing a display deviceaccording to an embodiment of the present invention may further includea plasma treatment process. The plasma treatment process may beperformed on the black matrix BM to surface-treat the black matrix BM.

Accordingly, thermal stability of the black matrix BM is increased, sothat a color solution may be stably confined in a color pattern formingprocess performed as a subsequent solution process. In addition, thecolor patterns may be stably formed by enhancing adhesion with the colorsolution. The above description is only exemplary, and in a method ofmanufacturing a display device according to an embodiment of presentinvention, the plasma treatment process may be omitted.

Referring to FIGS. 7, and 8E to 8H, a color pattern is formed on thedisplay substrate (S220). The color pattern may be formed by varioussuitable processes in addition to a photolithography process. Forexample, the color patterns CP-R, CP-G, and CP-B may be formed by asolution process, such as a dropping process or an ink-jet process.Alternatively, the color patterns CP-R, CP-G, and CP-B may be formed bya staining method, a printing process, or an electric deposition method.

In the present embodiment, a process of forming the color patterns CP-R,CP-G, and CP-B through an ink-jet process will be described as anexample. In the present embodiment, the color patterns CP-R, CP-G, andCP-B are directly formed on the thin film encapsulation layer TFE.

As illustrated in FIG. 8E, a color solution is provided to each ofregions exposed by the black matrix BM. The black matrix BM effectivelyacts as a dam for confining the color solution to a respective areaduring the ink-jet process.

For example, a first nozzle NZ-R provides a first color solution LG-R toa first opening, a second nozzle NZ-G provides a second color solutionLG-G to a second opening, and a third nozzle NZ-B provides a third colorsolution LG-B to a third opening.

In the present embodiment, the first to third color solutions LQ-R,LQ-G, and LQ-B are differently colored. Accordingly, the first to thirdnozzles LN-R, LN-G, and LN-B, which are distinguished from each other,are provided to respective regions exposed by the black matrix BM.

The above description is only exemplary, and color solutions having thesame or substantially the same color may be provided to the displaysubstrate DP according to an embodiment of the present invention, inwhich case a single nozzle may be used. Alternatively, in a method ofmanufacturing a display device according to an embodiment of the presentinvention, four or more nozzles may be provided, although the presentinvention is not limited to any one embodiment.

As illustrated in FIGS. 8F and 8G, a plurality of color solution layersLQ-R, LQ-G, and LQ-B, which respectively fill the openings formed in theblack matrix BM, are dried to respectively form the color patterns CP-R,CP-G, and CP-B. In FIG. 8F, illustrated is a process of providing heatHT to the color solution layer to cure the color solution layer. Theabove description is only exemplary, and the drying process is notparticularly limited.

The drying process may be performed at a temperature of about 150degrees (° C.) or below. For example, the color patterns CP-R, CP-G, andCP-B according to an embodiment of the present invention may be formedby drying and curing the color solution layers LQ-R, LQ-G, and LQ-B withheat of about 100 degrees (° C.). Therefore, it is possible to preventor reduce damage to the organic light emitting device OLED during thedrying process, so that the process stability is improved.

As a plurality of color solution layers LQ-R, LQ-G, and LQ-B are cured,moisture and the like contained in the solution layer may be removed.Accordingly, a plurality of color solution layers LQ-R, LQ-G, and LQ-Bmay vary in thickness before and after curing. Each of the plurality ofcolor solution layers LQ-R, LQ-G, and LQ-B may be thicker than each ofthe respectively corresponding color patterns CP-R, CP-G, and CP-B.

Furthermore, each of the thicknesses TH_(CP) of the color patterns CP-R,CP-G, and CP-B may be thinner than the thickness TH_(BM) of the blackmatrix BM that is adjacent the color patterns CP-R, CP-G, and CP-B.According to an embodiment of the present invention, because the blackmatrix BM and the color patterns CP-R, CP-G, and CP-B are formed bydifferent processes, and because the color patterns CP-R, CP-G, and CP-Bare formed by the ink-jet process, the black matrix GM and the colorpatterns CP-R, CP-G, and CP-B may have different thicknesses.

In the method of manufacturing a display device according to anembodiment of the present invention, the black matrix is formed througha photolithography process, and the color patterns are formed through aphotolithography process and another ink-jet process. Accordingly, apre-baking process performed at a high temperature, or a developingprocess exposed by a developing solution, and a subsequently performedpost-bake process may be omitted.

In the case of a post baking process of the photolithography process,the display substrate is exposed at a high temperature of about 220degrees (° C.) or higher for about tens of minutes. Alternatively,because the method of manufacturing a display device according to anembodiment of the present invention does not require other hightemperature processes, except for the curing process of about 100degrees (° C.) or below, damage to an organic layer by the hightemperature can be reduced or prevented.

In addition, because the method of manufacturing a display deviceaccording to an embodiment of the present invention does not furtherrequire either an additional developing process for forming colorpatterns, or a thermal curing process including soft baking or hardbaking performed before the development process, process time and costmay be saved. In addition, because only one photolithography process isperformed for forming a black matrix, damage to the display substrate DPotherwise caused by a plurality of photolithography processes may bereduced. As a result, reliability is improved.

Additionally, the color pattern CP of other embodiments may be formed bya staining method that is different from a photolithography process, ormay be formed by an electrical deposition.

As illustrated in FIG. 8H, a protective layer PTL is formed on the colorfilter layer CFL. The protective layer PTL is formed by depositing aninsulating material on the color filter layer CFL. The protective layerPTL may have a set or predetermined thickness so as to cover anon-uniform upper surface formed on the color filter layer CFL and toprovide a uniform flat surface.

According to the above description, in a method of manufacturing adisplay device according to an embodiment of the present invention, ablack matrix and a color pattern are formed through different processes.The black matrix may be formed by a photolithography process, and thecolor pattern may be formed by an ink-jet process. Accordingly, aplurality of photolithography processes may be omitted, so that processtime and cost are saved, and so that damage to the display substrate dueto the photolithography process may be reduced or prevented.

In addition, a display device according to the present inventionincludes a black matrix and a color filter layer including a colorpattern that is thinner than the black matrix. The color filter layer isdirectly formed on the display substrate. Therefore, the display devicebecomes thinner and may obtain flexibility, which is useful for afoldable display device.

The above-disclosed subject matter is to be considered illustrative andnot restrictive, and the appended claims and their equivalents areintended to cover all such modifications, enhancements, and otherembodiments, which fall within the spirit and scope of the presentinvention. Thus, to the maximum extent allowed by law, the scope of thepresent invention is to be determined by the broadest permissibleinterpretation of the following claims and their equivalents, and shallnot be restricted or limited by the foregoing detailed description.

What is claimed is:
 1. A display device comprising: a display substratedivided into a plurality of emission regions, and a non-emission regionadjacent the plurality of emission regions, the display substratecomprising: a display layer comprising a base substrate and a pixel onthe base substrate; and an encapsulation layer on the base substrate andcovering the pixel and comprising inorganic layers and an organic layerlocated between the inorganic layers; a barrier on the display substrateand including a plurality of openings overlapping a correspondingemission region from among the plurality of emission regions; and aplurality of color patterns filled in a corresponding opening from amongthe plurality of openings, wherein the barrier is on an upper surface ofthe encapsulation layer.
 2. The display device of claim 1, wherein theencapsulation layer is between the barrier and the base substrate. 3.The display device of claim 1, wherein a range of a thickness of theencapsulation layer is from about 1 μm to about 10 μm.
 4. The displaydevice of claim 1, further comprising a protective layer having a flatsurface on the barrier and the plurality of color patterns.
 5. Thedisplay device of claim 1, wherein each of the plurality of colorpatterns is thinner than a respective adjacent portion of the barrier.6. The display device of claim 1, wherein the pixel comprises: atransistor on the base substrate, an anode electrode connected to thetransistor, a cathode electrode on the anode electrode, and an emissionpattern located between the anode electrode and the cathode electrodeand overlapping a corresponding emission region from among the pluralityof emission regions.
 7. The display device of claim 1, wherein each ofthe plurality of color patterns and barrier is directly connected withthe upper surface of the encapsulation layer.
 8. The display device ofclaim 1, wherein the barrier has a grid shape in a plan view.